Combo Wood And Plastic Modular Storage Shed

ABSTRACT

The present invention provides a system or kit which includes wood and plastic components or plastic components only. These components can be readily assembled to form a structure with the use of a minimal number of tools. The components are precut so that measurements and cutting of the component materials is eliminated. This leads to a savings in wasted materials. The components are readily assembled using conventional fasteners and simple hand tools. The components have preformed notches and tabs in order to facilitate assembly of the components without the requirement for measurements. This assures that the components will be assembled correctly and eliminates the opportunity for inaccurate measurements and incorrect assembly. The roof and floor structures are formed from plastic panels which interlock together.

FIELD OF THE INVENTION

This invention relates generally to enclosures, such as utility orgarden sheds, constructed of wood and plastic materials. Morespecifically, the present invention relates to an enclosure includingwalls having wood framing and wood siding, a plastic panel roofing, anda floor made from plastic panels.

BACKGROUND OF THE INVENTION

Utility sheds are a necessity for lawn and garden maintenance, as wellas general all-around home storage space. Typically, items such as lawnmowers, garden tillers, snow blowers, wheel barrows, shovels, rakes,brooms and the like consume a great deal of floor space in a garage.This results in the homeowner parking his/her vehicles outside of thegarage.

The prior art has proposed a number of different storage buildings orutility sheds assembled from a kit which includes a plurality of blowmolded or extruded plastic panels and connectors. These kits are readilyassembled by a homeowner to form storage structures or utility sheds ofvarious sizes. These structures are generally suitable for the storageof hand tools and smaller lawn equipment. Typically, these kits requireextruded metal or plastic connector members having a specificcross-sectional geometry which facilitates an engagement between theconnector members and one or more of the blow molded plastic panelshaving a complimentary edge configuration. Due to the nature of themanufacturing process, blow molded plastic components cannot be formedwith the intricate shapes and/or sharp corners required for integratedconnectors. In addition, blow molded plastic components are hollow andcannot be formed with the integral strengthening ribs and gussets thatinjection molded panels can be formed with.

A particularly common structure for the connector members is the I-beamcross section. The I-beam defines free edge portions of the connectormember which fit within approximately dimensioned and located slots inthe panel members. U.S. Pat. No. D-371,208 teaches a corner extrusionfor a building sidewall that is representative of the state of the artI-beam connector members. The I-beam sides of the connector engage withthe peripheral edge channels of a respective wall panel, and therebyserve to join such panels together at right angles. Straight or in-lineversions of the connector members are also included in the kits to joinpanels in a coplanar relationship to create walls of varying length.

Extruded components generally require hollow longitudinal conduits forstrength. Due to the nature of the manufacturing process, the conduitsare difficult to extrude in long sections for structural panels. Thus,the panels require connectors to achieve adequate height for utilityshed walls. A common structure for connecting extruded members has acenter I-beam with upper and lower protrusions for engaging theconduits. However, wall panels utilizing connectors are vulnerable tobuckling under loads and may have an aesthetically unpleasingappearance. Moreover, roof loads from snow and the like may cause suchwalls to bow outwardly due to the clearances required between theconnectors and the internal bores of the conduits. U.S. Pat. No.6,250,022 discloses an extendable shed utilizing side wall connectormembers representing the state of the art. The connectors have a centerstrip with hollow protrusions extending from its upper and lowersurfaces along its length. The protrusions are situated to slidablyengage the conduits located in the side panel sections to create theheight required for utility shed walls.

The aforementioned systems can also incorporate roof and floor panels toform a freestanding enclosed structure such as a utility shed. U.S. Pat.Nos. 3,866,381; 5,036,634; and 4,557,091 disclose various systems havinginter-fitting panel and connector components. Such prior art systems,while working well, have not met all of the needs of consumers toprovide the structural integrity required to construct larger sizedstructures. Larger structures must perform differently than smallerstructures. Larger structures require constant ventilation in order tocontrol moisture within the structure. Large structures must alsowithstand larger wind and snow loads compared to smaller structures.Paramount to achieving these needs is a panel system which eliminatesthe need for extruded connectors to create enclosure walls which resistpanel separation, buckling, racking, and a roof system which allowsventilation while preventing weather infiltration. A further problem isthat the walls formed by the panels must tie into the roof and floor insuch a way as to unify the entire structure. Also, from a structuralstandpoint, the structure should include components capable ofwithstanding the increased wind, snow and storage loads required bylarger structures. From a convenience standpoint, a door must be presentwhich can be readily installed after assembly of the wall and roofcomponents. The door must also be comparable with the sidewalls andprovide ready access to the interior of the structure. Also, from aconvenience standpoint, the structure should permit natural as well asartificial lighting. The structure should be aesthetically pleasing inappearance to blend in with the surrounding structures.

There are also commercial considerations that must be satisfied by anyviable structure assembly system or kit; considerations which are notentirely satisfied by the state of the art products. The structure mustbe formed from relatively few components which are inexpensive tomanufacture by conventional techniques. The enclosure must also becapable of being packaged and shipped in a knock-down state. Inaddition, the system or kit must be modular and facilitate the creationof a family of enclosures that vary in size but which share common,interchangeable components.

Finally, there are ergonomic needs that an enclosure system must satisfyin order to achieve acceptance by the end user. The system must beeasily and quickly assembled using integrally formed connectorsrequiring minimal hardware and tools. Further, the system must notrequire excessive strength to assemble or include heavy component parts.Moreover, the system must assemble together in such a way so as not todetract from the internal storage volume of the resulting enclosure, orotherwise detract from the internal storage volume of the resultingenclosure, or otherwise negatively affect the utility of the structure.

SUMMARY OF THE INVENTION

The present invention provides a system or kit which includes wood andplastic components or plastic components only. These components can bereadily assembled to form a structure with the use of a minimal numberof tools. The components are precut so that measurements and cutting ofthe component materials is eliminated. This leads to a savings in wastedmaterials. The components are readily assembled using conventionalfasteners and simple hand tools. The components have preformed notchesand tabs in order to facilitate assembly of the components without therequirement for measurements. This assures that the components will beassembled correctly and eliminates the opportunity for inaccuratemeasurements and incorrect assembly. The roof and floor structures areformed from plastic panels which interlock together.

Accordingly, it is an objective of the instant invention to provide asystem or kit for assembly of a utility enclosure which utilizes precutwood and plastic components to create structures of varying dimensionsby using common components.

It is a further objective of the instant invention to provide a utilityenclosure system or kit which utilizes plastic components to secure andconnect wood components together.

It is yet another objective of the instant invention to provide autility enclosure system or kit which utilizes plastic structural frameand panel members having integrated connectors for creating enclosuresof varying sizes.

It is a still further objective of the instant invention to provide autility enclosure system or kit wherein the panel members includeintegrated connectors which accommodate plastic formation of the panelcomponents for increased structural integrity.

It is still another objective of the instant invention to provide autility enclosure system or kit which utilizes structural cornerassemblies for increased enclosure rigidity.

It is still another objective of the instant invention to provide autility enclosure system or kit which utilizes interlocking bosses andpockets to secure wall panels to a floor and/or roof.

It is still another objective of the instant invention to provide autility enclosure system or kit which utilizes roof and floor componentswhich interlock together for structural stability and the prevention ofincursion of water into the enclosure.

Other objects and advantages of this invention will become apparent fromthe following description taken in conjunction with any accompanyingdrawings wherein are set forth, by way of illustration and example,certain embodiments of this invention. Any drawings contained hereinconstitute a part of this specification and include exemplaryembodiments of the present invention and illustrate various objects andfeatures thereof.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a front perspective view of a first embodiment of the presentinvention;

FIGS. 2A-F are views of side and back panels of a first embodiment ofthe present invention;

FIGS. 3A-C are perspective views of the floor assembly and theinterlocking connection of the floor components of a first embodiment ofthe present invention;

FIGS. 4A and B are views of the assembly and connection of the rearpanel to the floor assembly of a first embodiment of the presentinvention;

FIGS. 5A-D are views of the assembly and connection of the right sidepanels to the floor assembly of a first embodiment of the presentinvention;

FIGS. 6A and B are views of the assembly and connection of the left sidepanels to the floor assembly and rear panel of a first embodiment of thepresent invention;

FIGS. 7A-C are views of the assembly and connection of the right sidepanels to the floor assembly and another side panel of a firstembodiment of the present invention;

FIGS. 8A and B are views of the assembly and connection of the rightside panels to each other of a first embodiment of the presentinvention;

FIGS. 9A and B are views of the assembly and connection of the left sidepanels to each other of a first embodiment of the present invention;

FIGS. 10A-C are views of the assembly and connection of the left sidepanels to each other of a first embodiment of the present invention;

FIGS. 11A-D are details of the left side panels of a first embodiment ofthe present invention;

FIGS. 12A and B are details of the connection between the side panelsand rear panels of a first embodiment of the present invention;

FIGS. 13A-C are views of the assembly and connections of the roofassembly to the side panels of a first embodiment of the presentinvention;

FIGS. 14A and B are views of the assembly and connection of thecomponents of the roof assembly to each other of a first embodiment ofthe present invention;

FIGS. 15A-D are views of the assembly and connections of the left doorpanel to the side panels of a first embodiment of the present invention;

FIGS. 16A and B are details of the connection of a handle to the leftdoor of a first embodiment of the present invention;

FIGS. 17A-D are views of the assembly and connections of the right doorpanel to the side panels of a first embodiment of the present invention;

FIGS. 18A and B are details of a roof support of a first embodiment ofthe present invention;

FIGS. 19A and B are details of a roof support of a first embodiment ofthe present invention;

FIGS. 20A and B are details of a roof support and the fasteners employedto secure it to the utility enclosure of a first embodiment of thepresent invention;

FIG. 21 is a front perspective view of a second embodiment of thepresent invention;

FIGS. 22A and B are perspective views of a corner panel secured to aside panel;

FIGS. 23A and B are perspective views of a corner panel secured to aside panel;

FIG. 24 is a view of an inside of a side panel with additional braces;

FIG. 25 is a perspective view of one of the braces in FIG. 24;

FIGS. 26A and B are perspective views of a side panel and a face frame;

FIGS. 27A and B are detailed views of the attachment of the face frameto a corner panel;

FIG. 28 is a perspective view of a top connector and a side panel;

FIGS. 29A and B are views of a top connector secured to a side panel;

FIG. 30 is a perspective view of a bottom connector and a side panel;

FIG. 31 is a perspective view of a bottom panel secured to a side panel;

FIG. 32 is a perspective view of a filler board between two back panels;

FIGS. 33A and B are perspective views of the filler board of FIG. 32secured to the two back panels;

FIG. 34 is a perspective view of support braces secured to the backpanels;

FIG. 35 is a perspective view of a support brace;

FIG. 36 is a perspective view of a bottom connector being secured to oneof the back panels;

FIG. 37 is a perspective view of the bottom connectors secured to theback panels;

FIGS. 38A and B are views of the back panel being secured to a floorpanel;

FIG. 39 is a perspective view of the back panel secured to a floorpanel;

FIG. 40 is a perspective view of a side and corner panels being securedto a floor panel;

FIG. 41 is a perspective view of a side and corner panels being securedto a floor panel;

FIG. 42 is a perspective view of a side, corner, and back panels securedto a floor panel;

FIG. 43 is a top perspective view of the side, corner and back panelssecured to the floor panel;

FIGS. 44A and B are top perspective views of the top connectors of theback and side panels;

FIGS. 45A and B are top perspective views of the header being installedbetween the side panels;

FIG. 46 is a perspective view of the roof panel;

FIG. 47 is a cross sectional view of the roof securement taken alonglines A-A in FIG. 21;

FIG. 48 is a cross sectional view of the roof securement taken alonglines B-B in FIG. 21;

FIGS. 49A and B are views of hinges on the left door;

FIGS. 50A and B are views of hinges on the left door;

FIG. 51 is a view of a handle being installed on the left door;

FIGS. 52A and B are views, with the back panels removed, of the slidebolt being installed on the left door;

FIG. 53 is a view of a hasp to be installed on the doors;

FIG. 54 is a view of the hasp and handles on the doors; and

FIG. 55 is an exploded view of the second embodiment of the enclosure ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

While the present invention is susceptible of embodiment in variousforms, there is shown in the drawings and will hereinafter be describeda presently preferred, albeit not limiting, embodiment with theunderstanding that the present disclosure is to be considered anexemplification of the present invention and is not intended to limitthe invention to the specific embodiments illustrated.

FIGS. 1-20B, which are now referenced, show isometric and exploded viewsof a system or kit for the assembly of a first embodiment of the presentinvention. A utility enclosure or shed is generally illustrated at 10.The enclosure or shed 10 includes a right side wall assembly includingright side front panel 12 and a right side rear panel 14, a back wallassembly including a back right panel 16 and a back left panel 18, and aleft said wall assembly including a left side front panel 20 and a leftside rear panel 22 (FIGS. 2A-F). These panels are secured to one anotherin a manner which will be described hereinafter. Panels 12-22 aresecured to a floor assembly 24, FIG. 3A.

The floor assembly includes at least two floor panels 26 and 28 whichare secured to each other to form the floor of the enclosure. As can beseen in FIGS. 3A-C, the floor panels 26 and 28 are secured to each otheralong a longitudinal edge of each panel. The panel 26 includes anupwardly facing groove 29, FIG. 3B, which extends along a longitudinaledge thereof. Adjacent the groove 29 is a lip or upturned ridge 30. Thelip or ridge 30 extends along the length of groove 29 and is adjacentthereto. Floor panel 28 includes a downwardly facing groove 32, FIG. 3B,which extends along a longitudinal edge thereof. Adjacent groove 32 is alip or ridge 34 which extends along the length of the groove 32. Lip 34is constructed sized to mate with groove 29. Lip 30 is constructed andsized to mate with groove 32. The structural inter-fitting of the lipsinto the grooves provides structural integrity and support for theconnection of the floor panels 26 and 28 to each other. This structuralrelationship also provides a seal or boundary which prevents theintrusion of water or other fluids from passing from the bottom of thepanels to the top of the panels. This structure therefore prevents wateror other fluids from entering into the enclosure or shed from below. Inaddition, fasteners, such as screws, are utilized to connect the floorpanels 26 and 28 together.

FIGS. 4A and B illustrate the manner in which a rear panel 16 is securedto a floor panel 26. The rear panel 16 includes a plurality of tabs 36formed to or secured along a bottom portion or edge. The tabs 36 areformed as a curved member which includes a bend of substantially 90degrees, as seen in FIG. 4B. A peripheral portion of both floor panels26 and 28, include apertures or slots 38, FIGS. 4A and B. The tabs 36fit into the apertures and engage the peripheral portion of the floorpanel 26 to secure the rear panel 16 onto the floor panel 26. Thisengagement is accomplished by tilting the top of the rear panel 16downwardly prior to inserting the tabs 36 into the slots 38. Next, panel16 is returned to its upright, vertical position. This moves the outeredge 37 of tabs 36 below the peripheral portion of the floor panel andprevents the rear panel 16 from moving upwardly and thus becomingdetached from the floor panel. Rear panel 16 also includes apertures 40and 42 which will be described hereinafter.

A right side rear panel 14 is illustrated in FIGS. 5A-D. It is securedto the floor assembly 24 utilizing the same construction and elementsthat rear panel 16 utilizes to be secured to the floor assembly 24. Tabs44 on the bottom portion or lower edge of right side rear panel 14 fitinto apertures or slots 46 on the peripheral portion of the floor panel26 to secure the right side rear panel 14 onto the floor panel 26. Thisengagement is accomplished by tilting the top of the right side rearpanel 14 downwardly prior to inserting the tabs 44 into the slots 46.Next, panel 16 is returned to its upright, vertical position. This movesthe outer edge of tabs 44 below the peripheral portion of the floorpanel and prevents the right side rear panel 14 from moving upwardly andthus becoming detached from the floor panel. Right side rear panel 14also includes a corner member or flap 48 (FIG. 5B) which is hingedlysecured to panel 14 along an edge portion. Corner member 48 engages andis secured along an edge 50 of rear panel 16 (FIG. 5C). Corner member 48fits into a groove 52 which extends along the edge 50. This enables theouter surface of the corner member 48 to be flush with the outer surfaceof rear panel 16. This presents an aesthetically pleasing appearance tothe outer portion of the enclosure 10. Fastening elements 54, such asscrews, are employed to secure corner member 48 to rear panel 16. Thefastening elements 54 pass through the apertures 40 in panel 16 andengage corner member 48, thus securing panels 16 and 14 to each other,as illustrated in FIG. 6A. A tool 56, such as a screwdriver, is employedto connect fastening elements 54 to panel 14.

A right side front panel 12 and right side rear panel 14 are illustratedin FIGS. 7A and 8A. The right side front panel 12 includes a pluralityof tabs 58 on the bottom portion or lower edge of right side front panel12 which fit into apertures or slots 60 on the peripheral portion of thefloor panel 28 to secure the right side front panel 12 onto the floorpanel 28. This engagement is accomplished in a manner similar to thesecuring of panel 14 to floor panel 26. The right side front panel 12includes a groove 62 which extends along the length of the panel. Theright side rear panel 14 includes a groove 64 which extends along thelength of the panel. Grooves 62 and 64 are constructed and arranged tomate with each other so as to enable panels 12 and 14 to be joinedtogether. The grooves 62 and 64 further provide a connection betweenpanels 12 and 14 which does not distract from the inner or outersurfaces of the panels. The grooves also present an aestheticallypleasing appearance of a single said wall of the utility enclosure.Fasteners 54 are utilized to secure panels 12 and 14 together, asillustrated in FIGS. 8A and B. Fasteners 54 pass through apertures 40 inpanel 12 and are screwed in panel 14, thus securing panels 12 and 14together.

FIGS. 9A and B illustrate the right and left back panels 16 and 18secured to floor panel 26. The back panel 18 is secured to the floorpanel utilizing tabs 36 on the back panel and apertures 38 on the floorpanel 26; similar to the manner in which back panel 16 is secured tofloor panel 26. Back panels 16 and 18 also include grooves 66 and 68respectively along their length. Grooves 66 and 68 are constructed andarranged to mate with each other in a manner similar to grooves 62 and64. Fasteners 54 pass through apertures 40 in panel 16 and are screwedinto panel 18 so as to secure panels 16 and 18 together. This connectionis similar to the connection which joins panels 12 and 14 together.

FIGS. 10A-C describe the connection of left side panels 20 and 22 toeach other, and their installation onto floor panels 26 and 28. Leftside front panel 20 includes a plurality of tabs 70 formed to or securedalong a bottom portion or edge. The tabs 70 are similar to tabs 36 onpanel 16. Tabs 70 fit into apertures 72 on floor panel 28. Panel 20 issecured to floor panel 26 in a manner similar to that of panel 16 beingsecured to floor panel 26. Left side rear panel 22 also includes tabs(not shown) along a bottom portion thereof. These tabs fit intoapertures in floor panel 28 and thus secure panel 22 to floor panel 28in a manner similar to that employed to secure panel 20 to floor panel26. Left side panels 20 and 22 include channels 74 and 76, respectively,which extend along their length. Channels 74 and 76 are constructed andarranged to mate with each other so as to enable panels 20 and 22 to bejoined together. The grooves 74 and 76 further provide a connectionbetween panels 20 and 22 which does not distract from the inner or outersurfaces of the panels. The grooves also present an aestheticallypleasing appearance of a single said wall of the utility enclosure.Fasteners 54 are utilized to secure panels 20 and 22 together. Fasteners54 pass through apertures 40 in panel 22 and are screwed in panel 20,thus securing panels 20 and 22 together.

FIGS. 11B-C illustrate the connection between left side rear panel 22and left back panel 18. Left side rear panel 22 includes a corner memberor flap 78 (FIG. 11B) which is hingedly secured along an edge portion.Corner member 78 fits into a groove 80 which extends along an edge ofpanel 18. This enables the outer surface of the corner member 78 to beflush with the outer surface of panel 18. This presents an aestheticallypleasing appearance to the outer portion of enclosure 10. Fasteningelements 54, such as screws, are employed to secure panels 22 and 18together, similar to the manner in which the other panels are secured toeach other. FIGS. 12A and B illustrate the manner in which fasteningelements 54 secure panels 22 and 18 together.

FIGS. 13A-C illustrate a roof assembly for the utility enclosure 10. Theroof assembly includes a front roof panel 82 and a rear roof panel 84.The roof panels 82 and 84 are curved along their lateral dimension. Thisconstruction provides a curved surface on top of enclosure 10 whichenables rain, snow and other elements of the weather to readily roll offthe roof. This prevents accumulation of water, etc. on the roof whichcan lead to water leaking into the enclosure 10. Each of the side panels12, 14, 20 and 22 have at least one projection 86 positioned along anupper edge of the panel. In a preferred embodiment, there are twoprojections 86 on each panel. Each of the roof panels 82 and 84 have atleast one and preferably two recesses or channels 88 positioned on aninside edge at each end of the panels, as illustrated in FIGS. 13A andB. Each of the roof panels is separately placed on the enclosure 10. Theroof panels are placed atop the side panels, offset to the front or rearof the enclosure. The panels are then slid or moved toward the center ofthe enclosure 10. The projections 86 on the side panels are then slid inand engage the recesses 88. This then locks the roof panels in place onthe enclosure without the use of separate fasteners. Each of the roofpanels 82 and 84 are provided with a channel 90 and 92, respectively,along a longitudinal edge thereof. The channels 90 and 92 are formed ascompliments to each other so that when the channels 90 and 92 areengaged they form an interlocking seal between roof panels 82 and 84(FIG. 14B). This interlocking seal holds the panels together andprevents the intrusion of water or other fluids into the enclosure.

The front of the enclosure 10 includes a door assembly which comprisestwo door panels. A left door panel 94 (FIG. 15A) and a right door panel96 (FIG. 17A). The door panels are hingedly secure to the side panels,as illustrated in FIGS. 15-17. Left door panel 94 is hingedly secured toleft front panel 20 with three hinges 98, 100, and 102, as illustratedin FIGS. 15B, 15C and 15D respectively. Hinges 98, 100, and 102 are slidinto apertures on panel 20. These apertures retain the hinge members andprevent their disengagement from the side panel. The apertures alsopermit the hinge members to pivot which permits the doors to open andclose. Door panel 94 is also provided with a handle 104 the assist theopening and closing of the door panel. Handle 104 is secured to the doorpanel with fasteners 106.

Right door panel 96 is hingedly secured to left front panel 12 withthree hinges 108, 110, and 112, as illustrated in FIGS. 17B, 17C and 17Drespectively. Hinges 108, 110, and 112 are slid into apertures on panel12. These apertures retain the hinge members and prevent theirdisengagement from the side panel. The apertures also permit the hingemembers to pivot which permits the doors to open and close. Door panel96 is also provided with a handle (not shown) to assist the opening andclosing of the door panel. The handle is secured to the door panel withfasteners similar to 106.

FIGS. 18A and 18B illustrate a roof brace 114 secured to left side panel20 with fasteners. The roof brace provides additional support for theroof panels. This additional support is useful to prevent collapse ofthe roof under heavy snow loads, etc. FIGS. 19A and 19B illustrate theroof brace 114 secured to right side panel 12 with fasteners. FIG. 20Billustrates the fasteners 116 used to secure the roof brace 114 to theside panels.

FIGS. 21-52, which are now referenced, show isometric and exploded viewsof a system or kit for the assembly of a second embodiment of thepresent invention. A utility enclosure or shed is generally illustratedat 200. The enclosure or shed 200 includes a right side panel 202, aleft side panel 204, a back panel 206 (FIG. 22A), corner panels 208(FIG. 22A), a roof panel 210, a floor panel 212 and front doors 214 and216. The right side panel, left side panel, corner panels, back panelsand doors are formed mainly from wood. These panels are secured to eachother in a manner which will be described hereinafter.

A corner panel 208 includes a plurality of wooden boards or siding 218(FIG. 22B). Each board or siding 218 is provided with a “tongue side”220 along one longitudinal edge and a “groove side” 222 along anopposite longitudinal edge (FIG. 22B). The tongue side of each boardfits into the groove side of an adjacent board, as illustrated in FIG.22B, to provide a water tight joint between the boards. This type ofconnection also provides a secure, structural connection betweenadjacent boards. A plurality of braces 224, are secured to an inner sideof the corner panels. These braces 224 hold the boards or siding 218together and provide structural support for the boards 218. While threebraces 224 are illustrated, any number can be employed on each of thecorner panels.

Support braces 226 are illustrated in FIGS. 22A and B, the supportbraces 226 are secured to the top and bottom portions of the side panel204. Each of the boards or siding 218 on the side panel 204 are securedto the support braces. The ends of the support braces 226 are providedwith apertures 228 (FIG. 22B). Fastening devices, such as screws, areset in to these apertures to secure the braces 226 of the side panel tothe boards 218 of the corner panel (FIGS. 22B, 23A and B).

Additional support braces 227 are provided on the side panel between thetop and bottom support braces (FIG. 24). These additional support bracesprovide structural strength and rigidity to the side panel. Theadditional support braces are secured to the corner panel 208 in thesame manner that the top and bottom support braces were secured to thecorner panel.

A face frame member 228 is secured to a corner panel (FIGS. 26A and B).A longitudinal edge of the face frame 228 is provided with a “groove”230 along the length thereof. The groove 230 is constructed and arrangedto mate with the “tongue” 220 along the edge of a board 218 of thecorner panel 208. Fasteners, such as screws, pass through apertures 232on the face frame. These fasteners are used to secure the face frame 228to the corner panel 208 (FIG. 27A and B). Portions of the face frame arecut away at 234 to allow the face frame to fit around the braces 224 onthe corner panel 208. A similar face frame member 229 (FIG. 45A) issecured to an opposite corner panel on the other side of the enclosure.

A top connector member 236 is secured along the top edge of a side paneland corner panel, as illustrated in FIGS. 28, 29A and 29B. The topconnector member 236 includes a plurality of apertures 238. Fasteners,such as screws, are passed through these apertures and secure the topconnector member 236 to the side and corner panels (FIG. 29A). The topconnector member 236 is made of a plastic or resin material.

A bottom connector member 240 is secured along the bottom edge of a sidepanel and corner panels, as illustrated in FIGS. 30 and 31. The bottomconnector member 240 includes a plurality of apertures 242. Fasteners,such as screws, are passed through these apertures and secure the bottomconnector member 240 to the side and corner panels (FIG. 31). The bottomconnector includes a plurality of tabs 241. The bottom connector panel240 is made of a plastic or resin material.

The back panel 206 of the enclosure includes a left back panel 244 and aright back panel 246 (FIG. 33A). This is mainly for manufacturing andshipping purposes. A filler board 248 is designed to be inserted betweenthe left and right back panels, and provide a support to secure the leftand right back panels together. A “groove” is provided along onelongitudinal edge of filler board 248 and a “tongue” is provided alongan opposite longitudinal edge of the filler board. These tongue andgroove connections mate with comparable tongue and groove connections onboards 218 of the left and right back panels (FIG. 33B).

FIGS. 34, the left and right back panels are provided with supportbraces 226 along a top and bottom edge thereof. These support braceshold the boards 218 together during shipping, prior to assembly andafterwards. Additional support braces 250 extend across the widths ofthe left and right back panels. These additional braces 250, togetherwith the filler board 248, securely hold the left and right back panelsto each other and thus form the back panel 206. The support braces 250are provided with apertures 252. Fasteners, such as screws, are passedthrough these apertures and secure the support braces 250 to the backpanels and the corner panels.

Bottom connectors 254 are secured along the bottom edge of the backpanel 206. As illustrated in FIG. 36, there are two bottom connectorssecured to the bottom edge of panel 206. While two bottom connectors areillustrated, any number of connectors can be employed. The bottomconnectors 254 are made of a plastic or resin material. The bottomconnectors 254 are provided with tabs 256 (FIG. 38B). These tabs aresimilar to tabs 36 on the back panels of the first embodiment of thepresent invention. Tabs 256 fit into or slots, not shown, on the floorpanel 212 (FIG. 38A). The back panel 206 is tilted downwardly and thetabs 256 are inserted into the slots on the floor panel. Next the backpanel is tilted to its upright position (FIG. 39). The back panel isthen slid to the right, as indicated by the arrow. This locks the tabs256 into the slots and prevents the back panel from separating from thefloor panel. The floor panel is made from a plastic or resin material.This permits the enclosure to be set on the ground without the danger ofthe wood boards rotting. Also, the floor panel prevents the intrusion ofwater and other fluids into the enclosure.

FIGS. 40 and 41 illustrate the manner in which the left side panel 204and corner panels 208 are secured to the floor panel 212. The side andcorner panels are tilted downwardly. Next, tabs 241 on the bottomconnector of the side panels are inserted into slots, not shown, on thefloor panel 212. Finally, the side and corner panel assembly is tiltedupwardly into its final upright position (FIG. 42).

Top connectors 258 are installed on the top edge of the back panel 206.Top connectors 258 are secured to the support braces 226 with fasteners,such as screws. The top connectors 236 and 258 serve as means to attachand secure the roof to the enclosure, as will be described hereinafter.The junction between top members 236 and 258 is illustrated in FIGS. 44Aand B.

FIG. 45A and B, a header member 260 is secured to the left and rightface frame members 228 and 229. Apertures 262 are provided on the headerwhich permit fasteners, such as screws, to secure the header to the faceframe members. In a preferred embodiment the header 260 is made frommetal. Other materials can also be used for the header.

FIG. 46-47, roof panel 210 is secured to the top connectors 236 and 258.The roof panel is placed on top of the connectors and then slid towardthe front of the enclosure. The left and right top connectors 236 areprovided with tabs 264. These tabs slide into “L” shaped grooves 266which are formed in the bottom edges of the roof panel 210. This nowlocks the roof panel onto the enclosure. Roof panel 210 also includestabs 268 which engage the top connectors 258 on the back panel. Tabs 268help to lock the roof panel in place and prevent it from sliding offonce it has been installed on the enclosure.

FIGS. 49A and B illustrate the left door 214 and hinges 270 which areemployed to secure the door to the face frame 228. Fasteners, such asscrews, are used to secure the hinges 270 to the door and the faceframe. FIGS. 50A and B also illustrate the manner in which the door 214is secured to the face frame. In a preferred embodiment, the edges ofthe door 214 and the face frame 228 are mortised to permit the hinges tobe mounted flush with the surfaces of the door and face frame, asillustrated in FIGS. 50A and B.

FIG. 51 illustrates the manner in which a door handle 272 and face plate274 are secured to door 214. A fastener 276 is employed to secure thehandle 272 and face plate 274 to the door. A similar handle 278 and faceplate 280 are secured to the right hand door 216 in the same manner(FIG. 54). A slide bolt 282 is secured to the top of the left door 214(FIG. 52B). The slide bolt moves up and down to engage and disengage anaperture in header 260. When the slide bolt engages header 260 it locksthe door 214 in a closed position. To open the door, one simply lowersthe slide bolt 282 until it disengages the header. The door 214 can nowbe opened.

FIG. 53 illustrates a hasp 284 which is installed on the doors 214 and216 to lock the door in a closed position. The hasp includes a leftportion 286 and a right portion 288. The right portion 288 includes apivotable locking member 290. The locking member 290 fits throughaperture 292 in the left portion 286. The locking member can then bepivoted so that it cannot pass through the aperture. This actioninterlocks the left and right portions of the hasp together. Since theleft and right portions are mounted on the left and right doorsrespectively, this action also locks the doors 214 and 216 of theenclosure in a closed position. A lock, such as a padlock, can also beplaced through the aperture 294 of the locking member 290. This enablesthe enclosure to be securely locked and prevents unauthorized intrusion.

All patents and publications mentioned in this specification areindicative of the levels of those skilled in the art to which theinvention pertains. All patents and publications are herein incorporatedby reference to the same extent as if each individual publication wasspecifically and individually indicated to be incorporated by reference.

It is to be understood that while a certain form of the invention isillustrated, it is not to be limited to the specific form or arrangementherein described and shown. It will be apparent to those skilled in theart that various changes may be made without departing from the scope ofthe invention and the invention is not to be considered limited to whatis shown and described in the specification and any drawings/figuresincluded herein.

One skilled in the art will readily appreciate that the presentinvention is well adapted to carry out the objectives and obtain theends and advantages mentioned, as well as those inherent therein. Theembodiments, methods, procedures and techniques described herein arepresently representative of the preferred embodiments, are intended tobe exemplary and are not intended as limitations on the scope. Changestherein and other uses will occur to those skilled in the art which areencompassed within the spirit of the invention and are defined by thescope of the appended claims. Although the invention has been describedin connection with specific preferred embodiments, it should beunderstood that the invention as claimed should not be unduly limited tosuch specific embodiments. Indeed, various modifications of thedescribed modes for carrying out the invention which are obvious tothose skilled in the art are intended to be within the scope of thefollowing claims.

1. A modular utility shed construction system utilizing molded plasticstructural panels comprising: a floor assembly for enclosing a bottom ofsaid utility shed, said floor assembly including a plurality oflike-configured floor panel members, one of said floor panel membersincluding a groove extending along a longitudinal edge of said floorpanel, another of said floor panel members including a lip extendingalong a longitudinal edge of said another floor panel member, said lipof said another floor panel member engaging said groove of said onefloor panel member thereby securing said one floor panel member to saidanother floor panel member, a groove extending around a perimeter ofsaid floor assembly, a plurality of apertures located within said grooveextending around said perimeter of said floor assembly; a pair of sidewall assemblies for enclosing left and right side sides of said utilityshed, said side wall assembly enclosing said left side of said utilityshed including a front side panel and a back side panel, said wallassembly enclosing said right side of said utility shed including afront side panel and a back side panel; at least two tabs along a loweredge of each of said front and back side wall panels, said tabs beingconstructed and arranged to fit into said plurality of apertures locatedon said floor assembly when said front and back side wall panels aretilted away from a vertical position, said tabs locking said front andback side wall panels to said floor assembly and preventing removal ofsaid front and back side panels from said floor assembly when said frontand back side panels are moved to a substantially vertical position; aback wall assembly for enclosing a back portion of said utility shed,said back wall assembly including a left back wall panel and a rightback wall panel secured together to form said back wall assembly, atleast two tabs along a lower edge of each of said left and right backwall panels, said tabs being constructed and arranged to fit into saidplurality of apertures located on said floor assembly when said left andright back wall panels are tilted away from a vertical position, saidtabs locking said left and right back wall panels to said floor assemblyand preventing removal of said left and right back wall panels from saidfloor assembly when said left and right side panels are moved to asubstantially vertical position; a roof assembly for enclosing an upperportion of said utility shed, said roof assembly including a pluralityof roof panels secured together to form said roof assembly, a pluralityof recesses located along a perimeter of each said roof panel; aplurality of projections located along a top edge of each of said frontand back side wall panels, said plurality of projections on said frontand back side wall panels engaging said recesses on said roof panelsthereby locking said roof assembly onto said front and back side wallpanels; and a door assembly enclosing a front of said utility shed andpermitting access to said utility shed, said door assembly including atleast two door panels.
 2. The modular utility shed construction systemof claim 1 wherein each said left and said right side wall assemblyinclude an upper edge which is higher at its midpoint than at its ends.3. The modular utility shed construction system of claim 2 wherein saidroof assembly is curved along a traverse cross section, the midpoint ofthe traverse cross section is higher than the ends of the cross section.4. The modular utility shed construction system of claim 3 wherein theupper edge of said left and said right wall assemblies are the sameshape as the transverse cross section of the roof assembly, whereby saidroof assembly completely engages said left and said right side wallassemblies.
 5. The modular utility shed construction system of claim 1wherein each of said roof panels includes a channel along a longitudinaledge, each of said channels being a complementary shape for the othersaid channel whereby, when said channels of said roof panels are placedtogether, they form a seal which prevents the intrusion of water andother elements through the roof assembly and into the utility shed. 6.The modular utility shed construction system of claim 1 wherein saiddoor assembly includes a plurality of door panels, each said door panelis secured to a side wall assembly, one of said door panels includes alatching device, said latching device is operable from an interior ofsaid door panel.
 7. The modular utility shed construction system ofclaim 1 wherein said door assembly includes a plurality of door panels,each said door panel is secured to a side wall assembly, each of saiddoor panels includes a handle for operatively opening and closing saiddoor panels.
 8. The modular utility shed construction system of claim 1including a roof brace, said roof brace extending between said side wallassemblies and contacting an interior surface of said roof assembly. 9.The modular utility shed construction system of claim 1 wherein eachsaid side wall back panel includes a flap which is hingedly secured tolongitudinal edge of said side wall back panel, each of said left andsaid right back wall panels include a groove extending along alongitudinal edge which is adjacent to said side wall assemblies, saidflap is constructed and arranged to fit into groove to provide a meansto secure said side wall back panels to said back wall panels, said flapand said groove are constructed and arranged to not extend outwardly ofa plane of the outer surfaces of said side wall back panels and saidback wall panels.
 10. A utility shed construction kit comprising: afloor assembly for enclosing a bottom of said utility shed, a pluralityof apertures located around a perimeter of said floor assembly; a pairof side walls for enclosing left and right sides of said utility shed,said side walls formed of a plurality of vertical members securedtogether in a common plane; a pair of corner panels secured to each saidleft and said right wall assembly, each said corner panel formed of aplurality of vertical members secured together; a back wall assembly forenclosing a back portion of said utility shed, said back wall assemblyincluding a left wall panel and a right wall panel, each said left andright back wall panel formed of a plurality of vertical members securedtogether in a common plane; a filler member secured to and connectingsaid left and right back wall panels to each other, said filler memberis similar to said vertical members in said back wall assembly; and adoor assembly enclosing a front of said utility shed and permittingaccess to said utility shed, said door assembly including at least twodoor panels.
 11. The utility shed construction kit of claim 10 whereineach said vertical member includes a groove extending along alongitudinal edge and a tongue extending along an opposite verticaledge, said tongue is constructed and arranged to fit into said groove toprovide a structural and weather tight seal between adjacent verticalmembers.
 12. The utility shed construction kit of claim 10 including aplurality of substantially horizontal support braces extending acrosseach said side panel, each said back panel, and each said corner panel.13. The utility shed construction kit of claim 10 including additionalcross braces extending across both said back wall panels and joiningsaid back wall panels together to form said back wall assembly.
 14. Theutility shed construction kit of claim 10 including a top connectorextending along a top edge of each said side wall assemblies and saidcorner panels.
 15. The utility shed construction kit of claim 14including a top connector extending along a top edge of each said backwall panels.
 16. The utility shed construction kit of claim 10 includinga bottom connector extending along a bottom edge of each said side wallassemblies and said corner panels.
 17. The utility shed construction kitof claim 17 including a bottom connector extending along a bottom edgeof each said back wall panels.
 18. The utility shed construction kit ofclaim 17 wherein each said bottom connector includes a plurality oftabs, said tabs being constructed and arranged to fit into saidplurality of apertures in said floor assembly when said side wallassemblies and said back wall assembly are tilted away from a verticalposition, said tabs locking said side wall assemblies and said back wallassembly to said floor assembly and preventing removal of said side wallassemblies and said back wall assembly when said side wall assembliesand said back wall assembly are moved to a substantially verticalposition.
 19. The utility shed construction kit of claim 15 wherein eachsaid top connector includes a plurality of tabs, said tabs engaging aplurality of apertures in said roof assembly when said roof assembly isslid onto said utility shed whereby said roof assembly is securely heldonto said utility shed.